Method of assembling a non-metallic biopsy forceps jaw

ABSTRACT

A biopsy forceps jaw device and method of assembling, comprising pivotally mounting to a single flat support having a single aperture a threaded, self-centering proximal end and a pointed distal end, an integrally connected non-metallic jaw assembly having a cutting plane. The integrally connected non-metallic jaw assembly pivots about a common axis within the single aperture allowing for rotation of the integrally connected non-metallic jaw assembly within the cuffing plane. A pair of actuating wires for moving the integrally connected non-metallic jaw assembly from a closed position to an open position is attached to the integrally connected non-metallic jaw assembly. The threaded self-centering proximal end of the single flat support and the pair of actuating wires are inserted into a tubular member. The integrally connected non-metallic jaw assembly and the single flat support are centered within the tubular member through the threaded self-centering proximal end.

This is a divisional application of prior application Ser. No.09/878,308 filed Jun. 12, 2001 now U.S. Pat. No. 6,440,085.

FIELD OF THE INVENTION

This invention relates in general to method of assembly for a biopsyforceps jaw and a biopsy forceps jaw and more particularly to a methodof assembly for a non-metallic biopsy forceps jaw and for thenon-metallic biopsy forceps jaw itself used for the removal of tissuesamples from a patient.

BACKGROUND OF THE INVENTION

A number of different types of biopsy forceps devices have beendeveloped for taking tissue samples. Some of the biopsy devices take theform of a forceps design with opposing jaws or radial jaws in which thejaws have intermeshing teeth. When activated, the teeth cut the desiredtissue and the tissue is stored within the jaw itself. In general thesedevices have the majority of their design made out of metalliccomponents. This is specifically the case for the biopsy jaw itself. Ingeneral the method of assembly for most of these devices requiresmeticulous effort to align and secure the metallic components of thejaw. This results in costly and time consuming assembly.

The desire to find a less costly and less complicated method of assemblyhas resulted in the use of some non-metallic components. Examples ofprior art methods of assembly and biopsy forceps jaw devices that havebeen devised to address the aforenoted problems, include, U.S. Pat. No.6,041,679 issued on Mar. 28, 2000 to Slater. This patent relates to anon-metallic end effector for use in an endoscopic surgical toolincludes a metallic core for strength and for providing a selectedelectrode surface on the end effector. Selectively conductive endeffectors are manufactured by insert molding a non-metallic or ceramicor other non-conductive body around a metallic or otherwise conductivecore. More specifically, the method of manufacturing includes an endeffector for an endoscopic surgical instrument having an actuationmeans, comprising: forming a metallic skeleton by a process chosen fromcasting, stamping or photochemically milling; and molding anon-conductive body around said metallic skeleton. The non-conductivebody having a proximal end with means for coupling to the actuationmeans, and a distal end with means for cutting, gripping, clamping, orotherwise contacting tissue.

U.S. Pat. No. 5,647,115 which issued on Jul. 15, 1997, relates to a jawassembly of an endoscopic biotome is formed by cutting a hemisphericalend of a spring metal cylinder with electrical discharge or lasermachining equipment to provide opposed jaw cups.

Although the prior art addresses some of the issues described above, itdoes not address a method of assembly for a non-metallic biopsy forcepsjaw device that allows for easy assembly and the use of less costlyparts.

SUMMARY OF THE INVENTION

An object of one aspect of the present invention is to provide animproved method of assembly of a non-metallic biopsy forceps jaw deviceand a non-metallic biopsy forceps jaw.

In accordance with one aspect of the present invention there is provideda method of assembling a biopsy forceps jaw device, comprising pivotallymounting to a single flat support having a single aperture a threaded,self-centering proximal end and a pointed distal end, an integrallyconnected non-metallic jaw assembly having a cutting plane. Theintegrally connected non-metallic jaw assembly pivots about a commonaxis within the single aperture allowing for rotation of the integrallyconnected non-metallic jaw assembly within the cutting plane. A pair ofactuating wires for moving the integrally connected jaw non-metallicassembly from a closed position to an open position are attached to theintegrally connected non-metallic jaw assembly. The ribbed proximal endof single flat support and the pair of actuating wires are inserted intoa tubular member. The integrally connected non-metallic jaw assembly andthe single flat support are centered within the tubular member throughthe threaded self-centering proximal end.

Conveniently, the integrally non-metallic jaw assembly may be an upperjaw and a lower jaw, wherein a cutting edge is insert molded and/orsnap-connected to the lower jaw for cutting tissue. The upper and lowerjaws may be snap-connected to one another.

Preferably, the threaded self-centering proximal end of the single flatsupport may be screwed into the tubular member thereby self-centeringthe jaw assembly in the tubular member.

In accordance with another aspect of the present invention there isprovided a non-metallic flexible biopsy jaw assembly for a biopsyforceps device which may be inserted through an endoscope for theremoval of body tissue from a body cavity, comprising a tubular member,a single flat support having a single aperture and a threaded,self-centering proximal end and a pointed distal end. The proximal endis screwed directly into the tubular member and the single flat supportis self-centered within the tubular member.

An integrally connected non-metallic jaw assembly having a cutting planeis mounted pivotally about a common axis within the single aperture ofthe single flat support for rotation of the integrally connected jawassembly within the cutting plane of the integrally connected jawassembly. A pair of actuating wires are snap-connected to the integrallyconnected jaw assembly and are slidable relative to the tubular memberand the single flat support for moving the integrally connected jawassembly from a closed position to a open position when activated.

Advantages, of the present invention include the use of non-metallicmaterials for the biopsy jaws thereby allowing the snap-connections ofthe upper and lower jaws and the actuating wires into the jaws.Furthermore, the proximal end of the single flat support is threaded insuch a way that the support alone self centers the jaw assembly withinthe tubular member. The assembly of the device in conjunction with thecomponents is such that it is not costly, as well as reducing theoverall time required for assembly. Furthermore, the use of non-metalliccomponents makes the device cheaper and therefore disposable if desired.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of the preferred embodiments are provided hereinbelow by way of example only and with reference to the followingdrawings, in which:

FIG. 1 in a perspective view, illustrates a non-metallic biopsy forcepsjaw in accordance with a preferred embodiment of the present invention.

FIG. 2 in an exploded view, illustrates the non-metallic biopsy forcepsjaw of FIG. 1.

FIG. 3 in an exploded view, illustrates the lower jaw of thenon-metallic biopsy forceps jaw.

FIG. 4 in a perspective view, illustrates the lower jaw of non-metallicbiopsy forceps jaw of FIG. 1.

FIG. 5 in a top view, illustrates the upper jaw of the non-metallicbiopsy forceps jaw of FIG. 1.

FIGS. 6a-c in a cross sectional views taken along the line 6—6,illustrates the snap-connection of the upper and lower jaws of thenon-metallic biopsy forceps jaw of FIG. 1.

FIG. 7 in a perspective view, illustrates the lower jaw of non-metallicbiopsy forceps jaw of FIG. 1.

FIG. 8 in a side elevational view, illustrates the non-metallic biopsyforceps jaw of FIG. 1 in a closed position.

FIG. 9 in a side elevational view, illustrates the non-metallic biopsyforceps jaw of FIG. 1 in an open position.

In the drawings, preferred embodiments of the invention are illustratedby way of example. It is to be expressly understood that the descriptionand drawings are only for the purpose of illustration and as an aid tounderstanding, and are not intended as a definition of the limits of theinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1 and 2, there is illustrated in a perspective andexploded views, a non-metallic flexible biopsy jaw assembly for a biopsyforceps device which may be inserted through an endoscope for theremoval of body tissue from a body cavity in accordance with a preferredembodiment of the present invention. The non-metallic flexible biopsyjaw assembly 10 includes a tubular member 12 and a single flat support14. The single flat support 14 has a single aperture 16, a threaded,self-centering proximal end 18 and a pointed distal end 20. The threadedself-centering proximal end 18 of the single flat support 14 may bescrewed directly into the tubular member 12. The threaded self-centeringproximal end allows for the single flat support and the non-metallicflexible biopsy jaw assembly 10 to be self-centered within the tubularmember 12.

The non-metallic flexible biopsy jaw assembly 10 further includes anintegrally connected non-metallic jaw assembly 22. The integrallyconnected non-metallic jaw assembly 22 has a cutting plane and ismounted pivotally about a common axis within the single aperture 16 ofthe single flat support 14 for rotation of the integrally connectednon-metallic jaw assembly 22 within the cutting plane of the integrallyconnected non-metallic assembly 22. A pair of actuating wires 24 aresnap-connected to the integrally connected non-metallic jaw assembly 22and are slidable relative to the tubular member 12 and the single flatsupport 14. The actuating wires 24 move the integrally connectednon-metallic jaw assembly 22 from a closed position to an open positionwhen activated.

Referring to FIG. 3, the integrally connected non-metallic jaw assembly22 may be further defined as a lower jaw 26 and a upper jaw 30. Thelower jaw 26 may further comprise of a cutting edge 27. The cutting edge27 may be metal blade or insert that is insert molded and/orsnap-connected into the lower jaw 26.

Referring to FIGS. 4, 5 and 6 a-c, the integrally connected non-metallicjaw assembly 22 further includes a single stepped pivot hole 28 in thelower jaw 26, and a flexible pin 32 in the upper jaw 30. The flexiblepin 32 of the upper jaw 30 passes through the single aperture 16 of thesingle flat support member 14 and is snap-connected to the stepped pivothole 28 of the lower jaw 26.

The flexible pin 32 may have a pronged and shaped end 34 for engagementwithin the stepped pivot hole 28. The stepped pivot hole 28 has a narrowentrance 36 into the stepped pivot hole 28 and a wider portion 38. Thepronged and shaped end 34 of the flexible pin 32 flexes and engages thenarrow entrance 36 and registers with the wider portion 38 of thestepped pivot hole 28.

Referring to FIG. 7, the integrally connected non-metallic jaw assembly22 further includes a stepped aperture 40 in each of the lower and upperjaws 26 and 30. Referring to FIG. 2, the actuating wires 24 furthercomprise of distal ends 42 that are inserted through the tubular member12, and proximal ends 44 having shaped protuberances 46. The shapedprotuberances 46 of the actuating wires 24 register within the steppedapertures 40 of the lower and upper jaws 26 and 30 in a snap-connection.

Referring to FIGS. 2, 8 and 9, there is illustrated in accordance withanother preferred embodiment of the present invention, a method ofassembling a Non-metallic biopsy forceps jaw device 10. The method ofassembly includes pivotally mounting to the single flat support 14through the single aperture 16 of the single flat support 14, theintegrally connected non-metallic jaw assembly 22. The integrallyconnected non-metallic jaw assembly 22 can pivot about the common axiswithin the single aperture 16 allowing for rotation of the integrallyconnected non-metallic jaw assembly 22 within the cutting plane.

The integrally connected non-metallic jaw assembly 22, and morespecifically the lower and upper jaws 26 and 30, are snap-connected toone another, by passing the flexible pin 32 of the upper jaw 30 throughthe single aperture 16 and registering the flexible pin 32 within thestepped pivot hole 28 of the lower jaw 26. The snap-connection betweenthe upper and lower jaws 30 and 26 allows easy assembly of the device10.

The pair of actuating wires 24 for moving the integrally connected jawnon-metallic assembly 22 from a closed position to an open position aresnap-connected to the upper and lower jaws 30 and 26. Specifically, theshaped protuberances 46 of the actuating wires 24 register within thestepped apertures 40 of the upper and lower jaws 30 and 26 in a similarfashion to that described for the connection between the upper and lowerjaws 30 and 26.

The threaded self-centering proximal end 18 of single flat support 14and proximal ends 42 of the pair of actuating wires 24 are inserted intothe tubular member 12. The integrally connected non-metallic jawassembly 22 and the single flat support 14 are centered within thetubular member 12 through the threaded self-centering proximal end 18 ofthe single flat support 14. The threaded self-centering proximal end 18of the single flat support 14 is screwed into the tubular member 12thereby self-centering the entire jaw assembly 10 in the tubular member12. The tubular member 12 may be either flexible or rigid.

As discussed above the integrally non-metallic jaw assembly may be anupper jaw 30 and a lower jaw 26, wherein a edge 27 may be insert moldedand/or snap-connected into the lower jaw 26. The cutting edge 27 may beinserted for enhanced cutting of the tissue. Specifically, the presentinvention allows for the sharp, cutting edge 27 of the lower jaw 26 tocontact the dull edge 48 of the upper jaw 30 in a similar fashion asseen with the use of a knife on a cutting board. This arrangementtherefore avoids the difficulties seen with radial jaws and the need forperfect alignment for the intermeshing teeth to effectively cut thetissue.

Other variations and modifications of the invention are possible. Allsuch modifications or variations are believed to be within the sphereand scope of the invention as defined by the claims appended hereto.

I claim:
 1. A method of assembling a non-metallic biopsy forceps jawdevice, comprising: (a) pivotally mounting to a single flat supporthaving a single aperture and a threaded centering proximal end and apointed distal end, an integrally connected non-metallic jaw assemblyhaving a lower jaw with a stepped pivot aperture, an upper jaw with aflexible pin and a cutting plane wherein said integrally connectednon-metallic jaw assembly pivots about a common axis within said singleaperture allowing for rotation of said integrally connected non-metallicjaw assembly within said cutting plane; (b) attaching to said integrallyconnected non-metallic jaw assembly a pair of actuating wires for movingsaid integrally connected jaw assembly form a closed position to an openposition; (c) inserting said pair of actuating wires into a tubularmember; (d) screwing said threaded centering proximal end of said singleflat support into said tubular member for centering said integrallyconnected non-metallic jaw assembly and said single flat support withinsaid tubular member; (e) inserting into said lower jaw a cutting edge;(f) registering said flexible pin of said upper jaw within said steppedaperture of said lower jaw.
 2. A method as claimed in claim 1, whereinsaid flexible pin has a pronged and shaped end for engagement withinsaid stepped pivot aperture.
 3. A method of assembly as claimed in claim2 wherein said stepped pivot aperture has a narrow entrance into saidstepped pivot aperture and a wider portion whereby said pronged andshaped end of said flexible pin flexes and engages said narrow entranceand expands into said wider portion of said stepped pivot aperture.
 4. Amethod of assembly as claimed in claim 3 wherein said pronged and shapedend of said flexible pin locks said upper jaw to said lower jaw in asnap-connection.
 5. A method of assembly as claimed in claim 1 whereinsaid upper and lower jaws each have a single stepped aperture forreceiving said actuating wires.
 6. A method of assembly as claimed inclaim 5 wherein said actuating wires further comprises distal ends forinsertion into said tubular member and proximal ends having shapedprotuberances.
 7. A method of assembly as claimed in claim 6 whereinsaid shaped protuberances of said actuating wires register within saidstepped apertures in a snap-connection.